Last week, I had the privilege of helping a manufacturing organization optimize its pull systems. This hands-on work inspired me to revisit a critical concept affecting many supply chains: the Bullwhip Effect.
The Bullwhip Effect happens when small changes in customer demand amplify as they move upstream, leading to massive fluctuations in production schedules, inventory levels, and supplier relationships. The result? Operational chaos, inefficiencies, and unnecessary costs.
But hereโs the good newsโit doesnโt have to be this way.
One powerful countermeasure is EPEI (Every Part Every Interval). This Lean technique focuses on leveling production by minimizing the time between producing every part in your product mix. When implemented effectively, EPEI can:
โ Stabilize production schedules
โ Reduce excess inventory buffers
โ Send clear, consistent demand signals to suppliers
Reflecting on this reminded me of my Lean journey. Over 25 years ago, I had the incredible opportunity to learn these concepts firsthandย from Mike Rother, Greg Ruddy, and Tom Luyster. Their coaching shaped the way I approach operational excellence to this day.
Are you ready to unlock your organization's full potential?
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